Relay mechanism



Aug. 24, 1943. c. F. wARRlcK RELAY MECHAN I S M Qriginal Filed May 18, 1938 ATTORNEYS.

Patented Aug. 24, 1943 RELAY MECHANISM Charles Fredricks Warrick, Detroit, Mich., assignor of one-half to The Imperial Brass Manufacturing Company, Chicago, Ill., a corporation o! Illinois Original application May 18, 1938, Serial No. 208,728, now Patent No. 2,249,994, dated July 22, 1941. Divided and this application July 15, 1940, Serial No. 345,655

(Cl. 17E-336) 5 claims.'

My invention relates to electrical controls and particularly magnetic actuated controls suitable for use in a variety 'of installations. Among the objects of my invention is to provide a new and improved electric control which is positive acting and sufficiently powerful so that movable parts therein of rugged construction can be shifted by a simplified circuit arrangement.

Another object is the provision of an electromagnetic relay mechanism provided with a new and improved overload release operating on the solder pot principle which is resiliently cushioned in such a manner that smooth operation is assured under all conditions.

Another object is embodied in the provision of a new and improved electro-magnetic relay provided with an overload release in which is incorporated an alarm which utilizes the magnetic attraction of a pole piece in the relay upon its armature.

Other objects include an electro-magnetic reof the pole piece and armature portion taken on the line --5 of Figure 1.

Figure 6 is a detail view of the universal spring mounting.

In the construction of electric control devices which must be made of such a rugged construction that they are suitable for throwing heavy switches for actuating alarms and like activities, it is necessary to construct the actuating portions in such a manner that they can be supplied with a current strong enough to do the work desired without that current being so great as to jeopardize the safety of any person coming in contact therewith. By providing a positive acting relay of this character the construction can be kept extremely simple so that an electrician with no more than a fundamental grounding in his art is capable of making adjustments and repairs without it being neceslay wherein the moving parts are resiliently and pivotally mounted one with respect to th'e other by means of spring connections or" such a nature that each piece can tilt in any direction with respect to the piece to which it is connected regardless of the position to whicheither has been previously tilted during operation of the device. The universal tilting construction also has for its object the embodiment of a novel mounting of the armature upon the lever` carrying it such that by use of the universally mounted springs the armature is always permitted to lie perfectly at upon the pole pieces during normal operation.

With these and other objects in view my invention consists in the construction, arrangement and combination of the various parts of my device whereby the objects contemplated are attained as hereinafter more fully set forth and pointed out in my claims and illustrated in the accompanying drawing in which:

Figure 1 is a top plan view of a commercial embodiment of my improved electric control device.

Figure 2 is across sectional elevation on the line 2-2 of Figure 1. i

Figure 3 is a cross sectional elevation on the line 3-3 of Figure 1.

Figure 4 is a cross section of a portion of Figure 1 taken on the line 4 4 which is at right angles to Figures 2 and 3.

Figure 5 is a partial cross sectional elevation sary to send the entire instrument back to the factory. rL'he extremely simple construction of my device also permits it to be built quickly and cheaply without sacriicing any neness oi adjustment in its operation and insures a product which can be sold to the public at a price commensurate with its usefulness.

My device in general consists of a transformer, or in some instances a condenser, having the primary side directly and permanently connected to a source of alternating current. The secondary side of the transformer includes a circuit necessarily insulated from the primary circuit and operable to actuate a magnetic relay, the armature of which is pivoted so that when actuated it is capable of throwing a heavy switch or of striking a bell or other similar functions requiring movement of an actuator arm with considerable force.

When such an electrical control device is used with an apparatus such for example as a pump, occasions arise when the pump might stall causing an overload and an excessive drain upon the line current causing temporary disruptions in the current conditions of the device, Accordingly, the control device has incorporated therein an overload release which is operable to disconnect the pump motor on such an occasion without disconnecting the circuit through the magnetic operative relay portion. To further insure against damage caused by an overloaded condition, the relay is constructed so that when the motor switch is tripped by the functioning of an overload release, the armature is tilted very slightly by means of lifting a resilient angle bracket at the side so that as the current con- 2 i i l tinues toA `iiowv throughfthe magnetic relayportionJthe armaturel produces a loud vibrant hum calling attention to the overloadedcondition so that it maybe readily corrected-beforea raise in the water level might reach such apoint as v to iiood the entire mechanism.

In order to-supply smooth and eiilcient Operation to a commercial embodiment of my inveninward and downward through aperforation at tion, certain innovations in the construction of an electrical control device working upon the principle herein disclosed become highly advantageous. These advantages comprise among other things what mightbe termed a universal resilient mounting for the armature and its extension arm, together with the switch mounting carried thereby. In addition to this .there is built into the control device an overload release and an alarm which utilizes the magnetic attraction of the armature as an audible warning of an overloaded condition.

This case isa division oi my co-pending application, Serial No. 208,728, lled May 18, 1938, now Patent No. 2,249,994, issued July 22, 1941.

The commercial device as shown in Figures 1 through 6 comprises an outer casing having a rear wall lull, bottom wall ll'and side walls |02 and |03. A transformeril is shown in Figure 1 having a primary coil and a secondary coil ||3. Line wires ||2 supply a permanent alternating current to the primary coil. A relay ||1 is shown provided with pole pieces i I8, the center one of which is wound with a relay coil |20. An armature |2| is carried by an extension |22 which is pivotally mounted by a special universal resilient mounting at the point |23 upon the rear wall |88 of the casing. The extension by means o a pair of insulated switch actuating arms |26 and |25 is adapted to carry respectively a switch bar |211 for controlling the relay circuit and a switch bar |25' for controlling the motor circuit, all the parts of which correspond in operation to the parts shown in the diagrammatic sketch of Figure l. of my said co-pending application, Serial No. 298,728, led May 18, 1938.

The parts shown in Figures 1 through 5 have been given the same characters above 100 as the corresponding parts in Figure 1 of my said copending application, as for example the transformer of Figure 1 of the said co-pending application indicated by the character ill is indicated by the character HU, in Figure l'herein, the

`armature 2l by the armature |2|, etc., in order to tie the commercial embodiment in with the general construction shown in diagrammatic form. Inasmuch as the diagrammatic sketch in Figure 1 of my said co-pending application clearly illustrates the method of making the connections embodied in Figures 1 through 5 herein the electrical connections of Figures 1 through 5 will not be described in detail. Instead the mechanical means facilitating the` electrical operations Will be emphasized.-

As shown in Figure 1 and more clearly by the sectional view in Figure 4, the extension |22 carrying the armature |2| is constructed of a somewhat Z shaped metal piece provided with apertures |26 and extending through each aperture is a projection |21 comprising a portion of the rear wall |00. 'Ihe projection fits loosely in the aperture and a pair of theseare supplied forming the universal resilient joints |23. A coil spring |28, details of which appear in Figure 6, rests upon the upper face of the extension |22 and surrounds the aperture |26 and projection |21. An extension |29 of the spring is hooked the end of the projection |21 thereby tending to press the extension |22 downwardly into position upon a suitable shoulder |30. An elongated coil spring |3I secured tothe outer rear end of the extension and a bracket |32 upon the rear wall tends to normally tilt the extension in an upward direction.

The switch arms |24 and |25 previously referred to are attached to the extension arm by resilient spring connections similar to that described for the'pivotpoint |23. These connections |33 comprise relatively largeapertures in the switcharm in which are inserted projections |34 of the extension to which are attached the novel coil springs |28 above described. By this manner of attachment the switch arm is enabled to tilt in any direction with respect to thel extension |22. At the opposite free end of the switch arm |25 there is provided the switch bar |25' resiliently mounted by means of a coil spring |35 upon the insulated switch arm and bearing contact points |36 and |31 for closing the motor circuit. A similar construction applies tothe switch arm |24 which actuates the relay switch for opening and closing the relay circuit.

In relay devices which are designed to operate at moderately high voltage, it is always the desire to have the armature set absolutely even upon the pole pieces and so that there will be no undesirable noice resulting from vibration by reason of having the armature tilted out of position. In the device disclosed herein, there is shown a novel and eiiicient mountingA for the armature which permits it to adjust itself absolutely iiat upon the pole pieces. This universal mounting comprises partly a universal spring arrangement such as has `been above described featuring projections |li forming a part of the laminated bar of the armature |2| which extend upward through slots M of the extension |22. Springs |28 engage the extension-and the projections extending therethrough-in the same manner as similar springs are used elsewhere throughout the pivoting portion of the armature. The springs by their action tend to draw the armature upward toward the extension |22.

To counteract the tendency of the springs to draw the armature toward the extension there is provided a downwardly extending lip |42 near the center of the extension. In the armature is provided an elongated slot |43 having somewhat of a trapezoidal shape with a width at the bottom approximately equal to the length of the lip |42, and the slot being somewhat wider and longer than the lip permits it to shift slightly in any direction once it is inserted therein. Laminated portions of the armature are bound together by rivets |44 at the sides and in the center and since the slot |43 extends down to the center of the armature the central rivet |44 is partially exposed in the slot. To accommodate the rivet there is provided a recess |45 at the lower edge of the lip |42 which is adapted to rock upon the exposed portion of the rivet in the nature of a pivot. Lugs or ears |46 are provided at the ends of the armature cooperable with inward extending portions |41 at the sides of the casing to prevent the armature being tilted upward beyond a certain point.

When the armature is assembled upon the extension the springs tend to draw the armature upwards against the lower edge of the lip |42. 'Ihis in turn permits the armature to tilt either endwise or crosswise or even in a diagonal direction so that although being held rmly in place it is so held by a universally acting resilient means which permits it to lie nat against the pole pieces regardless of any misadjustments or obstructions upon the same.

In case the motor should stall for some reason, there is provided in the electrical control device an overload release consisting of a plunger |50 of insulating material normally urged in an upward direction by spring means net shownv but retained by a means of a pawl attached to the plunger which engages a ratchet wheel |52. The ratchet wheel in turn is mounted upon a shaft journaled in a cylindrical solder pot |53 of more or less customary design. Around the solder pot there is wound a coil ol resistant wire |54 which is connected in series-with one of the wires leading to the motor. Normally the plunger is held in' a downward position because the solder in the pot being solid prevents rotation of the ratchet wheel |52. If there is an excessive calll for current in the motor circuit, raising the amperage, the coil |54 becomes hot enough to melt solder in the solder pot as soon as the iiow of current reaches a certain amount. Solder of this kind is carefully calibrated so as to melt at a predetermined temperature. When the solder melts the ratchet wheel |52 is permitted to rotate thereby permitting the plunger |55 to be urged upwards.

A wall of` insulating material separates the transformer coil from the relay coil and serves as a vertical guide for the plunger |50. In the wallthere is cut a slot |78 and extending through the slot is a projection secured to the plunger around Which is wound a spring' |55 having one end bent up sharply at the point l5?. Whenever the plunger is released by means of an overloaded condition it raises the spring |56 until the uppermost point |5`| engages the switch arm |25 butsince the opposite side of the spring |56 is not bent upwards no contact is made with the relay switch arm. Accordingly, when there is an overload the motor switch arm is raised breaking the motor circuit thereby cutting the motor and pump out of operation. Since the relay switch is unailected the armature remains held in position and the remainder of the device continues in operation unaiected by said overload condition. It is signiiicant that the overload release is of an extremely resilient character since both the spring |56 which lifts it is resilient as it also the support for the contact bridge |251,

Although the mechanism for disconnecting the motor under overload conditions is highly meritorious, an added precautionary measure is built into the relay consisting of an overload alarm. The principle of operation of the alarm is that of deliberately tilting the armature on the pole pieces so that vibration due to a relatively high alternating current may set up a distinct audible hum calling attention to the overloaded condition of the motor.

The overload alarm comprises primarily a bar |80 secured to the plunger |50 at a point slightly below the attachment of the spring |56. Attached to the .armature at each end is a resilient bracket |6| which extends over the bar |65, This bar is positioned on the plunger at such a point that whenever it has been raised suiciently to break the motor circuit as a result of overload, the bar |60 ascends into contact with the resilient brackets |6| tending to tilt them slightly. The tendency to tilt is a very small amount,

only enough to cause the armature to vibrate as a result of the alternating current producing thereby a penetrating audible hum calling attention to thc overload. If the warning given by the alarm is heeded there will be ample time to correct the condition in cases where the control might be used in connection with a sump pump and damage which might be caused by flooding of the system due to failure of the pump to operate may be avoided.

Some changes may be made in the construction and arrangement of my device without departing from the real spirit and purpose of my invention and it is my intention to cover by my claims any modified forms ofstructure or use of mechanical equivalents which may be reasonably included within their scope.

I claim as my invention:

1. In a magnetic actuated electric relay including a casing member and a pole piece therein, the combination of an armature actuated mechanism comprising a lever member, a universal spring connection member suspending one end of the lever relative to the casing, an-actuator member having its axis extending from the spring connection toward the pole piece and universal spring connections along the axis urging said actuator against the lever member, an armature member having an axis extending across the axis oi the actuator intermediate the spring connections and a universal spring connection attaching said armature member to said lever meinber and holding the armature away from the pole piece` said connection comprising in each case an aperture means o n one member and a projection on the other extending loosely therethrough and a coiled spring seated on the apertured member surrounding the projection on the other having an extension hooked into said projection te permit relative tilting of the members so connected in any direction.

2. In a magnetic actuated electric control device including a casing and a pole piece therein having separate spaced poles and having a portion bearing a coil, the combination of an armature actuated mechanism comprising a lever member pivoted to the casing and an elongated armature member extending over said poles, a plurality oi universal connections spaced along the armature member attaching the armature member to said lever member, and connections including a plurality of aperture means in one member and a plurality of corresponding projections in the other member exd tending loosely through the aperture means,

coiled springs positioned on one member about the respective projections on the other having extensions engaged in the projections adapted to resiliently urge the members in one direction at said respective spring locations, and a universally pivoted connection between said members adapted to limit movement of said members in the opposite direction and provide thereby a balanced universal connection therebetween.

3. In a magnetic actuated electric control device including a casing and a pole piece therein having spaced poles and having a portion bearing a coil, the combination of an armature mechanism comprising a lever member pivoted to the casing and suspended above the poles, an elongated armature member extending over said poles having a universal connection with said lever member, said connection including a pair of aperture means in one member and a pair of projections in the other member extending loosely through the aperture means, coiled springs positioned on one member about the 'respective projections on the other having extensions engaged in 'the projections adapted to resiliently urge the members in one direction, one of said members having a second elongated aperture means running parallel to the long dimension of the armature and having a rounded element extending thereinto and a corresponding elon-l gated projection on -said other member extending into said elongated aperture, said last projection having a recessed portion complementary to and engageable with said rounded element to limit movement of said members in the opposite direction and provide a balanced universal connection therebetween.

4. In a magnetic actuated electric control device including a casing and spaced electric wound pole elements therein having iiat exposed ends, the combination of a laminated armature positioning mechanism comprising an elongated armature member having a flat face normally exatively narrow recess between the lamiuations adjacent the midportion thereof including a rounded element in the recess and a lip on the other member extending loosely within the nari row'recess having a hollow portion engaging said rounded element forming a pivot between said members having limited lateral and longitudinal movement and opposing the force of said universal resilient supports tending to urge said members toward each other.

5. In a magnetic actuated electric control device including a casing and spaced electric wound pole elements therein, the combination of an armature" positioning mechanism comprising an elongated armature member extending over the ends of both poles, a lever member resiliently suspended adjacent the armature member, universally movable resilient supports attached independently to said armature member and to said lever member at points spaced one from another on opposite sides of a point midway between the ends of the armature member and having independent operation with respect thereto in a di# rection adapted to urge said members toward each other and to urge the armature away from the poles, one of said members having a relative- 1y narrow recess adjacent the midportion thereof and a lip on the other member extending loosely Within the narrow recess forming a pivot between said members remote from the points of attachment of vsaid resilient supports, said pivot having limited lateral and longitudinal movement and opposing the force of said universal resilient supports. Y

CHARLES FREDRICKS WARRICK. 

